Waterproofing method by using plastic panels

ABSTRACT

An improved waterproofing system for concrete slab of a flat roof on a building is disclosed. The invention concerns a construction method for installing on the concrete substrate a waterproofing layer comprising hollow plastic panels of designed size, different thickness, and the groove and the tongue joint, and installing a supplementary waterproofing layer using sheet membrane materials such as asphalt sheet, metal sheet and other sheets on the vertical surface, especially the parapet of roof. The invention further concerns a construction method for applying fluid-applied materials after reinforcement with fiber mesh on their joint line to connect plastic panels on substrate with sheet membrane layer on the vertical surface. The waterproofing layer of sloped step type, hollow plastic panels of different thickness permits fast drainage of stagnant water, which inhibits weather damage to the waterproofing layer.

BACKGROUND OF THE INVENTION

[0001] The invention provides an improved waterproofing system for the concrete slab of a flat roof on a building. More specifically, the invention relates to a construction method for installing a waterproofing layer by using a plastic panel of designed size on the concrete substrate, and installing a supplementary waterproofing layer by using a general sheet membrane materials such as asphalt sheet, metal sheet and other sheets on a vertical surface, especially parapet, and further relates to a multi-ply construction method for installing fluid-applied materials and reinforcing fiber meshes on the surface to connect the plastic panel layer on substrate with the sheet membrane layer on the vertical surface.

[0002] In the conventional waterproofing systems for the concrete substrate, especially roofs on buildings, a single-ply waterproofing system by using fluid-applied materials such as urethane or polymeric asphalt and cementitious materials, or sheet membrane materials such as thermoplastics, rubberized asphalt, vulcanized rubberized and stainless steel is well known.

[0003] However, the single-ply waterproofing system by using fluid-applied materials is apt to be affected by the surface condition of substrate, weather and condition of roof that will create blisters, debondment, tears, cracks, etc. It is also difficult to prevent water leakage at overlapped joint of sheet membrane. Thus, working expenses and hours come to increase in preparation for the substrate to protect defect of waterproofing layer.

[0004] In order to solve the problems of the single-ply waterproofing system by using the fluid-applied materials or sheet membrane, a proposal has been made to install a multi-ply or double-ply membrane such by using both fluid-applied materials and sheet membranes as a multiply waterproofing system of urethane and modified asphalt sheet, or a multi-ply waterproofing system of cementitious materials and stainless steel plate.

[0005] Although the proposed waterproofing system has solved some problems of the single-ply waterproofing system, other problems still remain unsolved as follows:

[0006] First, in case of the multi-ply waterproofing system of urethane and modified asphalt sheet, because both materials have a flexible property, it is difficult to make a sloped waterproofing layer adaptable for fast water drainage. Accordingly, there are many places where rain or snow is melted into water and stagnant on the waterproofing layer, thereafter-waterproofing layer is aged, faded, cracked and blistered. Because of the flexible property, this system does not withstand the pressure occurring from foot traffic and movement of objects for utility of a roof space.

[0007] Second, in case of the multi-ply waterproofing system of cementitious materials and stainless steel plate, it has shortcomings including debondment of the waterproofing layer between the materials and noise occurring when a workman walks on the waterproofing layer. Metal sheet is deformed by thermal expansion and contraction, and the overlapped joint bursts open. Thus, it is hard for a worker to carry and treat the metal sheet. For this reason, total construction period is delayed, and labor and construction costs are increased.

[0008] Third, since each material of the multi-ply waterproofing system has a different surface condition and adhesion mechanism, the system cannot gain a good adhesion to the materials after application. The problems of blistering, cracking and tearing caused by weather affect the overlapped part of sheet membrane during many application steps of the multi-ply waterproofing system.

[0009] Finally, because installation of the multi-ply waterproofing system is mainly made at the job site, carrying, mixing, application, curing and setting of a ventilation plate, and overlapping and sealing of seams in every material such as fluid-applied materials or sheets are affected by weather. These factors become the problem of defect of the waterproofing layer.

SUMMARY OF THE INVENTION

[0010] The present invention has an object to develop the sheet or fluid-applied material of the single-ply or multi-ply waterproofing system, and to provide the multiply waterproofing system which consists of the waterproofing layer by using the hollow plastic panel of designed size, holes and thickness on concrete slab of a flat roof on a building, and the supplementary waterproofing layer by using the general membrane materials such as asphalt sheets, metal sheets and other membrane sheets on the vertical elements, especially the parapet of roof.

[0011] The single-ply system by using fluid-applied materials for waterproofing a flat roof on buildings is apt to be affected by the surface condition of substrate, weather and condition of roof that will create blisters, debondment, tears, cracks, etc. In case of a single-ply system using sheet membrane, it is difficult to prevent water leakage at overlapped joint of sheet membrane. Thus, working hours and expenses increase in preparation for the substrate to prevent defect of waterproofing layer.

[0012] The invention provides the improved waterproofing system for the concrete slab of a flat roof on a building. More specifically, the invention relates to the construction method for installing the waterproofing layer by using a hollow plastic panel of designed size and thickness on concrete substrate, and installing the supplementary waterproofing layer by using sheet membrane materials on the vertical surface especially parapet of roof, and further relates to the construction method for installing the reinforcing fiber meshes on their joint line to connect plastic panels on substrate with sheet membrane layer on the vertical surface. A main property of the invention is to install the waterproofing layer of sloped-step type hollow plastic panels of a different thickness for fast drainage of stagnant water, which otherwise would cause physical damage in the performance of the waterproofing layer. Main contents of the invention are as follows:

[0013] 1. The plastic panel has several hollow parts in the inside thereof which may be configured in a variety of cross-sectional shapes, such as a circle or square. The upper or lower face of the edge parts in the plastic panel preferably has grooves and tongue joints for connection of the panels. This joint permits the space protection of the panel layer against the thermal expansion and contraction. Other panel connection methods may also be utilized.

[0014] 2. The plastic panel preferably has holes for fixing the panels on the substrate and for setting the special plates to ventilate the moisture existing in the space between the panels and the substrate.

[0015] 3. The waterproofing layer on substrate is installed as the sloped step to easily drain the stagnant water on the waterproofing layer made of the plastic panels of about 1 m×1 m in size (or about one square yard in size), and from 2-15 cm in thickness.

[0016] 4. The lines of the panels connected by the groove and the tongue joint are reinforced with sheet tape made of high strength of fiber, such as carbon fiber, glass fiber, armada fiber, etc. for preventing water penetration and movement of panels. At this time, reinforcing tapes are preferably adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 is a prospective view of plastic panel according to the invention;

[0018]FIG. 2 is a sectional view showing installation of waterproofing layer by using the plastic panel according to the invention;

[0019]FIGS. 3a to 3 c are sectional views of plastic panel according to the invention;

[0020]FIG. 4a is a top plan view of plastic panel according to the invention;

[0021]FIG. 4b is a bottom plan view of plastic panel according to the invention;

[0022]FIG. 4c is a top plan view of edge side plastic panel according to the invention;

[0023]FIG. 4d is a top plan view of plastic panel to install the ventilation plate;

[0024]FIG. 5 is a sectional view showing the sloped step shape of waterproofing layer for drainage of water after installation of plastic panel according to the invention;

[0025]FIG. 6 is a sectional view of the connecting joint part section of the plastic panel-waterproofing layer according to the invention;

[0026]FIG. 7 is a sectional view of the connecting part of the plastic panels and the sheet membrane;

[0027]FIG. 8 is a top plan view showing a method for fixing the plastic panel according to the invention;

[0028]FIG. 9 is a sectional view of plastic panels after installation of the ventilation plate; and

[0029]FIG. 10 is a sectional view of plastic panels applied the fluid-applied material and the sheet membrane.

DETAILED DESCRIPTION OF THE INVENTION

[0030] The waterproofing layer in accordance with the present invention comprises a main waterproofing layer by using a molded plastic panel of designed size on concrete substrate of a flat roof slab and a supplementary waterproofing layer by using the general membrane materials such as asphalt or polymeric membrane sheets on the vertical elements, especially the parapet of roofs on buildings.

[0031] The waterproofing method in accordance with the present invention defines a method for installing a waterproofing layer by using a plastic panel 1, as seen in FIG. 1, on concrete substrate 10 and a multi-ply waterproofing layer by using fluid-applied membrane 104 and sheet membrane 200 on vertical elements, especially the parapet 21 of a building roof, as seen in FIG. 2.

[0032] The main waterproofing layer 1 on the flat roof by using the plastic panel 1 and the supplementary waterproofing on vertical elements, especially the parapet 21 by using the sheet membrane 200 are connected by fluid-applied membrane 104, as seen in FIG. 2. The fluid-applied membrane 104 functions as a protective layer of plastic panel layer for watertightness and durability.

[0033] The plastic panel 1 as in FIG. 1 is factory-prepared. Important properties of the plastic panel 1 in the present invention are uniformity, homogeneity and quality such not affected from substrate condition as a factory-prepared product.

[0034] The upper or lower face of edge parts in the plastic panel 1 has grooves and tongue joints 3 for connection of each panel 1, as seen in FIGS. 1 and 4. The web of the groove and the tongue joint 3 is characterized as rigid joint, or has a space for distribution of stress occurring by a whole movement.

[0035] The plastic panel 1 has several hollow parts, which are preferably designed as a circle or square. The holes may be configured in a variety of cross-sectional configurations including, but not limited to, a quadrangle 2 a, circle 2 b or rectangle 2 c, as seen in FIG. 3.

[0036] The hollow plastic panel 1 is preferably manufactured of waterproof material, as seen in FIG. 1. The plastic panel 1 as a waterproofing layer on flat slab in buildings can be made in a different thickness ranging from 2 to 15 cm, which is high strength of plastic made with polymeric material that contains air layer such 2 a, 2 b and 2 c, as seen in FIG. 3. Some preferred purposes of hollow plastic panel 1 are to improve insulation performance, to make the panel lightweight and rigid, and to reduce its deformation by thermal effects, and reduce noise transfer by walking as an air layer in the inside of the waterproofing layer 1.

[0037] Furthermore, the hollow plastic panels 1 have four holes 5 in the corner of the panel, as seen in FIG. 4, FIG. 7 and FIG. 8, for installation on the substrate. These holes 5 are filled with the sealant 70 and a protection cap 50 after installation of the plastic panel with nail 40 on concrete substrate, as seen in FIG. 7.

[0038] Specially designed panels have a hole 4 in the middle of the panel 1, as seen in FIG. 4d and FIG. 9, to set a ready-made ventilation plate 30 and 31, as seen in FIG. 9, for ventilation of vapor existing between the waterproofing layer 1 and the concrete substrate 10, as seen in FIG. 2.

[0039] The proper slop of waterproofing layer is an important element for fast drainage of stagnant water in the installation of roof waterproofing system. In the invention, the plastic panel 1 can be manufactured in various sizes. Currently preferred sizes include 1 m×1 m or 1 yd.×1 yd., and range in thickness from 2 to 15 cm. The plastic panel 1 which varied in difference of thickness within 1 cm is connected with each other, those panels build up the waterproofing layer 1 as a kind of sloped step 1, as seen in FIG. 5. This formation has an advantage of fast drainage against stagnant water on the waterproofing layer 1.

[0040] One or more plastic panels 1 may be easily joined by the groove and tongue joint 3 without any special machine or tools, as seen in FIGS. 1 and 6. The groove and tongue joint 3 may firmly connect the plastic panels 1 adjacent to each other for installation of waterproofing layer 1, as seen in FIGS. 5 and 8, at the job site. Because this system preferably reinforces the connected line by using mesh 102 with fiber and liquid-applied materials 104, as seen in FIG. 6, problems of water leakage, blistering, cracking and tearing can be eliminated.

[0041] The connection joint part by the groove and tongue joint 3 is preferably reinforced with the fiber mesh 102 after sealing with sealant 70, as seen in FIG. 6. The fiber mesh 102 is attached after it is applied with a polymeric resin, such as epoxy resin bond 101 on joint line of panel 1. Fiber mesh 102 is impregnated by polymeric resin to reinforce the connection joint. These joint parts physically provide rigidity against movement and watertightness in the waterproofing system of the plastic panel 1. In the invention, the fiber mesh 102 may include a variety of possible reinforcing fibers, such as glass fiber, carbon fiber or armada fiber, for the purpose of reinforcing cracks in concrete structure. In forming the fiber mesh 102, woven fiber is preferable to unwoven fiber.

[0042] As seen in FIGS. 2 and 5, when the waterproofing layer 1 is exposed to weather, it can be covered with fluid-applied material 104 or cementitious material 104 to prevent aging of the plastic panel by weather.

[0043] The invention includes the multi-ply plastic panel preliminarily applied with membrane 104 such fluid or sheet materials for protection or reinforcement on the surface of the hollow plastic panel 1, as seen in FIG. 10. These membrane materials should be attached during manufacture, leaving a space of about 5 cm from each edge of the panel 1, as seen in FIG. 10. This space is reinforced by fiber mesh and fluid-applied membrane after each panel 1 is connected by the groove and tongue joint 3, at construction site.

[0044] The single-ply waterproofing system by using fluid or sheet membrane system in the conventional waterproofing system frequently has disadvantages including blisters, debondment, cracks, tears, etc. due to careless construction and surface condition of concrete substrate. Thus, the invention provides the improved solution method in order to overcome these disadvantages.

[0045] The invention protects the waterproofing layer and prevents blisters, cracks and aging by stagnant water, as well as puncture by exterior impact, such as dropping heavy objects or heavy walking on the waterproofing layer.

[0046] Molded plastic panels within the scope of the present invention may be prepared in a wide variety of sizes and shapes to suit different roof configurations. The plastic panels may easily be carried and handled thereby simplifying waterproofing construction compared to the conventional fluid-applied membrane or sheet membrane system.

[0047] The invention provides a watertight waterproofing layer and provides effective heat insulation by many air layers in the panel.

[0048] Although many details are shown in the invention, the invention is not limited to the preferred embodiments disclosed herein. For example, the plastic panels can be provided in various sizes and holes. For the purpose of providing a waterproofing layer against extreme weather conditions, multiple layers can be used. 

What is claimed is:
 1. A waterproofing method by using a plastic panel comprising the steps of: installing a main waterproofing layer comprising a plurality of hollow plastic panels of different thickness connected with groove and tongue joints, and installing a supplementary waterproofing layer comprising sheet membrane materials on roof vertical surfaces, especially the roof parapet, applying fluid-applied materials after reinforcement with fiber mesh on the groove and tongue joint line connected plastic panels on substrate, and connecting the main waterproofing layer on flat roof and the supplementary waterproofing layer on the vertical surface for improvement of watertightness and durability of waterproofing layer, installing the waterproofing layer of sloped step type by using hollow plastic panels of different thickness for fast drainage of stagnant water which will cause damage on performance of the waterproofing layer, and preliminarily applying the plastic panel with membrane such as fluid or sheet materials for protection or reinforcement on surface of the hollow plastic panel, the membrane materials being attached leaving a space of 5 cm from each edge of plastic panel in manufacturing of factory.
 2. A waterproofing method by using plastic panel as recited in claim 1 wherein said waterproofing method defines to install the main waterproofing layer by using the plastic panel on concrete substrate such as flat roof of buildings.
 3. A waterproofing method by using a plastic panel as recited in claim 1 wherein said plastic panels are molded in size of about 1 m×1 m from polymeric material.
 4. A waterproofing method by using a plastic panel as recited in claim 3 wherein said molded plastic panel has designed hollow holes of different thickness, groove and tongue joint, ventilation hole and fixing holes.
 5. A waterproofing method by using a plastic panel as recited in claim 4 wherein said designed holes have a shape of any of quadrangle, circle or rectangle.
 6. A waterproofing method using a plastic panel as recited in claim 4 wherein said different thickness has the range in thickness from 2 to 15 cm.
 7. A waterproofing method using a plastic panel as recited in claim 4 wherein said groove and tongue joint is made on the upper and lower surfaces of panel edge side, and made freely in size (web and depth of the groove or height and web of the tongue) to connect each panel.
 8. A water proofing method by using a plastic panel as recited in claim 4 wherein said ventilation hole is made in the middle of said plastic panel and covers with a ready-made ventilation plate for deflation of vapor existing between said waterproofing layer and concrete substrate.
 9. A waterproofing method by using a plastic panel as recited in claim 4 wherein said fixing hole is made in edge side of plastic panel.
 10. A waterproofing method by using a plastic panel as recited in claim 1 wherein said waterproofing layer forms the uniform flat layer or sloped step layer by use of same or different thickness panel by connection of the groove and tongue joint of each panel.
 11. A waterproofing method by using a plastic panel as recited in claim 1 wherein the connection line of groove and tongue joint of each panel is reinforced with fiber mesh, the fiber mesh being one of glass fiber, carbon fiber or armada fiber and attached by epoxy resin bond on the connection line.
 12. A waterproofing method by using a plastic panel as recited in claim 1 wherein said multi-ply plastic panel is preliminarily applied with membrane such as fluid-applied or sheet materials, and the membrane materials are attached during manufacturing, leaving a space of about 5 cm from each edge.
 13. A molded plastic panel useful in a waterproofing method comprising: a plurality of hollow channels having a quadrangle, square, circle or other geometric cross-sectional configuration; a groove and tongue joint manufactured on upper and lower surfaces of one or more panel edges to permit joining of adjacent panels; a ventilation hole and fixing holes; and wherein said plastic panels are molded in a size of about 1 m×1 m and have different thickness ranging from 2 to 15 cm. 